Climbing playsets

ABSTRACT

Climbing playsets and methods of manufacturing and constructing such playsets are provided. The playsets include interchangeable support members. Some playsets include compound members formed of two or more support members spliced together end-to-end.

TECHNICAL FIELD

This invention relates to climbing playsets for children and methods ofconstructing such playsets.

BACKGROUND

Play areas for children, such as backyards and community playgrounds,often include playsets (sometimes referred to as “jungle gyms”) designedto allow children to climb and may also include other play items such asswings and/or a slide. Such playsets are in some cases made of a woodsuitable or treated for exposure to the weather, for example cedar ortreated lumber. Climbing playsets may include integrated climbingstructures, for example climbing rungs that extend between uprightmembers of the playset. Including a variety of climbing options, such asclimbing rungs, ladders and steps, may facilitate development of achild's motor skills and enhance play.

SUMMARY

The present invention features climbing playsets formed at least in partwith interchangeable support members, and methods of constructing suchplaysets.

In some implementations, at least some of the support members areinterchangeable both within the playset and with support members used inone or more playsets having different configurations. For example, arelatively small number of different types of support members, e.g.,five or less, may be used to create a climbing playset, and differentcombinations of the same types of support members may be used to createa variety of climbing playsets having different configurations. Thisinterchangeability of support members simplifies both manufacturing andassembly of the playsets. Interchangeability also allows playsetmanufacturers and retailers to stock a relatively smaller number ofdifferent types of support members, thereby simplifying inventorycontrol. The lengths of the interchangeable members may be selected soas to reduce scrap wood generated when support members must be cut torequired lengths. In some cases, multiple support members are splicedtogether to create longer compound members, allowing tall climbingstructures to be built without the need for impractically long,single-piece support members.

The details of one or more embodiments of the invention are set forth inthe accompanying drawings and the description below. Other features andadvantages of the invention will be apparent from the description anddrawings, and from the claims.

DESCRIPTION OF DRAWINGS

FIGS. 1 and 2 are perspective views of two climbing playsets havingdifferent configurations.

FIG. 3 is a perspective view of a playset having an alternativeconfiguration.

FIGS. 4-4C are plan views of each of the four faces of a first supportmember used in the playsets shown in FIGS. 1 and 2.

FIGS. 5-5A are plan views of two faces of a second support member usedin the playsets shown in FIGS. 1 and 2. FIG. 5B is an end view of thesupport member shown in FIGS. 5-5A.

FIGS. 6-6A are plan views of two faces of a third support member used inthe playsets shown in FIGS. 1 and 2. FIG. 6B is an end view of thesupport member shown in FIGS. 6-6A.

FIGS. 7-7A are plan views of two faces of a fourth support member usedin the playsets shown in FIGS. 1 and 2. FIG. 7B is an end view of thesupport member shown in FIGS. 7-7A.

FIGS. 8-8A are plan views of two faces of a fifth support member used inthe playsets shown in FIGS. 1 and 2. FIG. 8B is an end view of thesupport member shown in FIGS. 8-8A. In the figures showing the second,third, fourth and fifth support members, the remaining two faces are notshown because they are blank, i.e., they do not include any drilledholes.

FIG. 9 is an enlarged, exploded detail side view of area A of FIG. 3,showing spliced upright members.

FIG. 10 is an enlarged detail view illustrating an alternative splicingarrangement.

FIG. 11 is an end view of an upright used in the splicing arrangementshown in FIG. 10.

FIGS. 12-15 are diagrams showing the footprints of various alternativeclimbing playsets, with the corresponding arrangements of supportmembers indicated.

DETAILED DESCRIPTION

Referring to FIG. 1, a climbing playset 10 includes a lower level 12, anupper level 14, and a top portion 16 extending above upper level 14.Upper level 14 includes a floor 15. Top portion 16 includes a singlehorizontal bar 17 extending between a pair of opposed vertical membersU1. Vertical members U1 are adapted to support one or more yardarms orother accessories, as will be discussed below, while bar 17 stabilizesthe vertical members and provides support for an optional roof canopy(not shown).

The playset 10 is constructed with a plurality of upright members 18.The upright members 18 are joined at their respective bases byhorizontal frame members 20, and at the top of the upper level byhorizontal frame members 22. The upright and horizontal frame membersdefine walls that are substantially open, i.e., that are not sided orotherwise covered. Dowels 61 extend between the upright members at thetop of the lower level, to join the upright members during the assemblyprocess and to support the floor 15.

Climbing rungs 26 extend between some of the upright members 18, toprovide integrated climbing ladders 24. The playset may also includepermanent or removable stair steps (not shown). Removable stair stepsfor use in climbing playsets are described in U.S. patent application______, the complete disclosure of which is incorporated herein byreference. In the playset shown in FIG. 1, each side of the playsetincludes a single ladder 24, and an adjacent door opening 25.

A climbing playset 100 having a different configuration is shown in FIG.2. In this playset, two opposite sides 102, 104 are the same as thesides of the playset shown in FIG. 1, i.e., these sides include a singleladder 24 and a door opening 25. The other two sides 106, 108 includetwo ladders 24, one on each side of a central door opening 126. Playset100 also differs from playset 10 in that playset 100 includes abox-shaped top portion 116 having three horizontal bars 117.

Another feature of the playsets shown in FIGS. 1 and 2 is theconstruction of the top portion 16. In some cases it may be difficult toobtain and/or store and ship long support members that extend from theground to the top of the top portion. Moreover, such long beams are notreadily interchangeable for use in shorter structures. Thus, in thepreferred embodiment shown in FIGS. 1-3, the upright members forming thetop portion are constructed by splicing together two or more shorterbeams, as will be discussed in detail below.

Each of the climbing playsets shown in FIGS. 1 and 2 can be constructedusing the five types of support members shown in FIGS. 4-8 as theupright members 18. These support members are labeled “XC1,” “L1,” “L2,”“U1,” and “U2,” respectively, in FIGS. 1 and 2, with “C” indicating thatthe support member functions as a corner member, “L” indicating that thesupport member functions as a lower upright, either alone or in acompound, spliced upright (discussed below), and “U” indicating that thesupport member functions as the upper portion of a compound, splicedupright.

The same support members can be used to construct a wide variety ofother climbing playsets, including, for example, the more complexplayset 300, shown in FIG. 3, which is larger than the playsets shown inFIGS. 1 and 2 and includes a roof structure 19.

The support members used to construct the playsets shown in FIGS. 1-3are shown in detail in FIGS. 4-8A.

Support member XC1 is shown in FIGS. 4-4C. Each corner support memberXC1 includes a plurality of pre-drilled holes that serve variouspurposes. For example, bolt holes 60 and 60A, drilled at right angles toeach other, are provided to allow a set of monkey bars or otheraccessory to be bolted to the member XC1, and bolt holes 64 and 64A areprovided to allow a yardarm or swing support to be bolted on. Bolt holes62 and 62A is provided to allow the bottom of each member XC1 to bebolted to a horizontal stabilizing member. These bolt holes are providedin pairs, drilled at right angles to each other, so that the cornersupport members can be oriented in any direction relative to theaccessories and/or stabilizing members. An additional five blind holes66 are dimensioned to receive climbing rungs 26. These holes are drilledinto the faces shown in FIGS. 4B and 4C, which are disposed 90 degreesfrom each other, so that the playset may include ladders on both sidesof each corner, as shown in FIGS. 2 and 3. The holes are blind holes sothat each of the faces opposite the faces with the holes is smooth andfree of holes in the ladder/door opening area.

Lower support members L1 and L2 are shown in FIGS. 5-5B and 6-6B,respectively. These support members are mirror images of each other,allowing a door opening to be formed with integrated ladders on eachside (e.g., door opening 126 in FIG. 3). Members L1 and L2 each includefour blind holes 68, dimensioned to receive climbing rungs 26, and onethrough hole 70, dimensioned to receive dowel 61 (shown, e.g., in FIG.3). Members L1 and L2 also each include a bore 54, drilled in the upperend of the member, and pilot holes 72, drilled perpendicular to bore 54,for receiving a splicing peg and screws to stabilize the peg, as will bediscussed below.

Upper support members U1, shown in FIGS. 7-7B, include a correspondingbore 54 and pilot holes 74, for receiving and securing the opposite endof the splicing peg. Members U1 also include a bolt hole 76 at the sameheight (when U1 is spliced to L1 or L2) as bolt holes 60 and 60A ofcorner support member XC1, and thus can be used to provide a secondattachment point for an accessory bolted to bolt hole 60 or 60A, e.g., aset of monkey bars that need to be secured at two or more points. MemberU1 also includes a pair of bolt holes 78 that may be used to securemember U1 to a yardarm or to horizontal member 22 (shown, e.g., in FIG.3) to provide stability to member U1. At its upper end, U1 includes ablind hole 80, to receive a horizontal stabilizing member (e.g., bar 17,FIG. 1), and a bolt hole 82 that allows a yardarm or other accessory tobe attached to the top of the playset, e.g., to allow a rope ladder tobe mounted at the top of the playset. U1 may have any desired length,but is generally sized so that, when spliced to L1 or L2, the splicedupright member will have a height that is about 2 to 5 feet higher thanthe height of corner support members XC I. This additional heightprovides the top portion or roof of the playset.

Member U2, shown in FIGS. 8-8B, is shorter than member U1 and isgenerally dimensioned so that when U2 is spliced to L1 or L2 theresulting spliced beam is substantially the same height as the cornersupport members XC1 (e.g., as shown in FIGS. 1-3). Like member U1,member U2 includes a bore 54, pilot holes 74 and bolt hole 76.

Any structural members that are not bolted on using the pre-drilled boltholes are generally lagged in place.

The playsets shown in FIGS. 1-3, and other playsets that may beconstructed using the same support members, are generally assembled byfirst connecting the corner members (XC1 support members) to the lowerupright members (L1, L2) to form the walls of the lower level. This isgenerally accomplished by first inserting climbing rungs to form theintegrated ladders and joining the uprights in the desired arrangementusing horizontal dowels, and then attaching the horizontal frame members20 at the bases of the uprights to stabilize the walls. Generally, thesesteps are performed for two sides of the playset at a time, and then thetwo two-sided assemblies are joined to form the completed lower level.After the lower level has been completed, pre-assembled floor platformsare installed at the top of the lower level, forming the floor of theupper level. After the floor is in place, the upper support members (U1,U2) are spliced to the lower support members (L1, L2) in the desiredconfiguration to form the upper level (using the shorter U2 members)and/or the top portion or roof (using the longer U1 members). Thehorizontal members 22 are then attached to the uprights to stabilize theupper level.

At appropriate points in the assembly process, braces, yardarms and/oraccessories may be added to the playset as desired.

The lower and upper members can be spliced together, to form the topportions shown in FIGS. 1 and 2, and the roof structure shown in FIG. 3,using any of a variety of splicing techniques. For example, as shown inFIG. 9 and area A of FIG. 3, upright 18 may be formed by boltingtogether two partial uprights 18A and 18B having corresponding splicingportions 50.

Alternatively, as shown in FIG. 10, the partial uprights can be splicedtogether by inserting a peg 52 into corresponding bores 54 (FIG. 11) inthe facing ends of partial uprights 118A and 118B. Peg 52 may be formedof any strong, rigid material, for example aluminum. The peg 52 is thenheld securely in place by a plurality of screws 56. This splicing methodwould be used with the support members shown in FIGS. 5-8, since thesemembers include the necessary bores and do not include the notchedstructure required for the method shown in FIG. 9.

Constructing the top portion support members using spliced compoundmembers generally reduces the cost of shipping, as compared to shippingfull length beams, and reduces material cost (shorter beams aregenerally more readily available and less expensive than longer ones)and waste.

The support members may have any desired dimensions. A set of supportmembers could, for example, have the following approximate dimensions(referring to the dimension lines shown in FIGS. 4-8A, with dimensionsgiven in inches):

XC1: A=3.75; B=1.88; C=1.88; D=15; E=25.75; F=36.38; G=47.00; H=57.63;I=75.25; J=84.13; K=98.00; total length=100.00.

L1/L2: A=3.25; B=2.00; C=1.00; D=15.00; E=25.75; F=36.38; G=47.00;H=57.63; I=1.88; J=3.75; total length=66.00.

U1: A=3.25; B=2.00; C=1.00; D=10.25; E=27.25; F=29.00; G=62.50; H=64.13;I=1.88; J=3.75; total length=66.00.

U2: A=3.25; B=2.00; C=1.00; D=10.25; E=30.00 (total length); I=1.88;J=3.75.

These dimensions can be varied to any desired extent. For example, thedimensions may be varied proportionally, e.g., by about 0 to ±50%, toprovide larger or smaller playsets having similar designs. If otherdesigns are desired, the dimensions can be varied in a non-proportionalmanner, and/or different drilling patterns may be used.

A number of embodiments of the invention have been described.Nevertheless, it will be understood that various modifications may bemade without departing from the spirit and scope of the invention.

For example, as mentioned above, the support members discussed hereincan be used to form many other types of playsets, in addition to thoseshown in FIGS. 1-3. Footprints of four other types of playsets that maybe constructed with these uprights are shown in FIGS. 12-15. In thesefigures, the designations “L1/U1,” “L1/U2,” etc., indicate splicedbeams. FIG. 12 shows the footprint of a square playset without a topportion, formed of four XC1 support members. FIG. 13 shows the footprintof a rectangular playset formed of four XC1 support members with asimple top portion formed of two compound members, each of whichincludes an L1 support member spliced to a U2 support member. FIG. 14shows a large square playset including four XC1 posts, with a topportion constructed of eight compound members constructed of splicedsupport members as indicated. FIG. 15 shows an octagonal gazebo withouta top portion, constructed of eight XC1 posts. These are merely a fewadditional examples of the many types of playsets that may beconstructed using the same set of support members.

Moreover, the same principles of interchangeability can be utilized tocreate different sets of support members having other lengths anddrilling patterns, for interchangeable use in other playset designs.

Accordingly, other embodiments are within the scope of the followingclaims.

1. A method of constructing two or more climbing playsets havingdifferent designs, the method comprising: (a) providing a set of supportmembers pre-drilled with holes in predetermined drilling patterns andcut to predetermined lengths, at least some of the support membershaving a common length and drilling pattern; (b) joining the supportmembers to form a first playset frame in which the support membersdefine upright members; (c) inserting climbing rungs into thepre-drilled holes to form one or more integrated climbing ladders in thefirst playset frame; and (d) repeating steps (b) and (c), using at leastsome support members that are substantially identical to the supportmembers used to form the first playset frame to form a second playsetframe having a different configuration.
 2. The method of claim 1 whereinthe set of support members consists of support members having no morethan five different drilling patterns.
 3. The method of claim 1 whereinthe set of support members consists of support members having no morethan three different lengths.
 4. The method of claim 2 wherein the setof support members consists of support members having no more than threedifferent lengths.
 5. The method of claim 1 wherein at least some of theupright members comprise compound members formed into a spliced uprightby joining two or more support members end-to-end.
 6. The method ofclaim 5 wherein all of the support members have a length of less than 9feet.
 7. The method of claim 6 wherein all of the support members have alength of less than 8 feet.
 8. A method for constructing climbingplaysets, said method comprising: (a) providing a library of plans forconstructing playsets of a substantial number of different playsetconfigurations; (b) providing a set of playset vertical support membersfor use in construction of the different playset configurations, the setof vertical support members consisting of wooden support members ofcommon length, the vertical support member defining pre-drilled holesarranged in a predetermined drilling pattern selected from a limited,finite number of drilling patterns, the limited, finite number ofdrilling patterns being substantially smaller than the substantialnumber of playset configurations; (c) from the library of plans,selecting a plan for constructing a playset of a predeterminedconfiguration; (d) from the set of playset vertical support members,selecting playset vertical support members designated by the selectedplan for constructing the playset of predetermined configuration; (e)joining the selected playset vertical support members to form a frame ofthe playset of predetermined configuration; (f) inserting climbing rungsinto the pre-drilled holes defined by adjacent selected playset verticalsupport members to form one or more integrated climbing ladders in theframe of the playset of predetermined configuration; and (g) repeatingsteps (c), (d), (e) and (f) using other plans selected from the libraryof plans and using playset vertical support members selected, asdesignated by the other plans, from the set of playset vertical supportmembers to form frames of the playsets of other, different predeterminedconfigurations, at least one of the playset vertical support membersselected from the set of playset vertical support members beingdesignated by multiple different plans for construction of playsets ofdifferent predetermined configurations.
 9. The method of claim 8 whereinstep (e) includes joining two or more vertical support membersend-to-end to form a spliced vertical member.
 10. The method of claim 9wherein all of the vertical support members have a length of less than 9feet.
 11. The method of claim 10 wherein all of the vertical supportmembers have a length of less than 8 feet.
 12. A climbing playsetcomprising a multi-level structure including a plurality of uprightmembers and a plurality of substantially horizontal tie members definingwalls that are substantially open, and a plurality of climbing rungsextending between at least one pair of the upright members to define anintegrated climbing ladder, wherein at least one of the upright membersis a spliced upright formed of two elongated pieces spliced togetherend-to-end.
 13. The playset of claim 12 wherein the playset includes atleast four spliced uprights.
 14. The playset of claim 12 wherein thespliced uprights define a top portion of the playset.
 15. A set ofplayset vertical support members for use in construction of asubstantial number of different playset configurations, the set ofvertical support members consisting of wooden support members of commonlength, the vertical support members defining pre-drilled holes arrangedin a predetermined drilling pattern selected from a limited, finitenumber of drilling patterns, the limited, finite number of drillingpatterns being substantially smaller than the substantial number ofplayset configurations, at least one of the playset vertical supportmembers selected from the set of playset vertical support members beingdesignated by multiple different plans for construction of playsets ofdifferent predetermined configurations.